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Textile dyehouse wastewater treatment : a case history

page 147

TEXTILE DYEHOUSE WASTEWATER TREATMENT:
A CASE HISTORY
Charles R. Kertell, Industrial Waste Engineer
Gilbert F. Hill, Engineering Supervisor
Gilbert Associates, Inc.
Reading, Pennsylvania 19603
Penn Dye and Finishing Company, Inc. operates a plant in the borough of Pine Grove,
Schuykill County, Pennsylvania, and engages in dyeing and finishing of synthetic knit fabrics. Process wastewater from the plant are initially treated in a series of three earthen
aeration basins. Following the aeration basins, alum and sodium hydroxide are added in a
rapid mix tank ahead of a flocculator/clarifier. After final pH adjustment, the clarified effluent is discharged to Swatara Creek.
The original wastewater treatment system, which consisted of the aeration basins and a
small sedimentation pond, was unable to meet effluent limitations. Beginning in 1975, Penn
Dye and Finishing Company, with Gilbert/Commonwealth as its consulting engineer, embarked on a program of studies, design and construction to upgrade and expand plant
wastewater treatment facilities. The upgraded system was designed and built to meet all
regulatory requirements of the U.S. Environmental Protection Agency (EPA) and the Pennsylvania Department of Environmental Resources (DER). The expanded industrial wastewater treatment facilities at Penn Dye have been in successful operation since September
1980.
Many small-to-medium size companies, such as Penn Dye, have limited financial resources
available for nonproductive facilities and have little prior experience in wastewater treatment. As a result, extensive investigations are often required to assure management of the
effectiveness of a proposed design. Project phases reviewed for this typical project include
bench scale treatability tests, onsite pilot plant study, obtaining permits, detailed design,
construction, startup and operation.
WASTEWATER FLOWRATES AND CHARACTERISTICS
Textile Dyeing Processes
Penn Dye processes only synthetic fabrics, including acetates, polyesters and nylon. Prior
to dyeing, aU fabric is cleaned and scoured for dirt and oil removal from the knitting process. Mostly dispersed dyes are used.
Both beam dyeing and jet dyeing are employed. In beam dyeing, the fabric is wrapped
around a perforated tube with one end closed and the other connected to a pump discharge.
The beam is immersed in a tub of dye solution, and the pump circulates dye through the
fabric by pumping from the tub into the perforated tube. Jet dyeing, primarily for polyesters, is performed in a closed pressure tub in which the fabric is guided through the dye-
stuff by a series of rollers.
Approximately 85-90% of the wastewater at Penn Dye results directly from the beam
dye machines and jet tubs. The remainder results from cooling water, washers, dryers, boiler
blowdown, filter backwash and other miscellaneous sources. Sanitary wastes are discharged
to the local municipal system.
147

TEXTILE DYEHOUSE WASTEWATER TREATMENT:
A CASE HISTORY
Charles R. Kertell, Industrial Waste Engineer
Gilbert F. Hill, Engineering Supervisor
Gilbert Associates, Inc.
Reading, Pennsylvania 19603
Penn Dye and Finishing Company, Inc. operates a plant in the borough of Pine Grove,
Schuykill County, Pennsylvania, and engages in dyeing and finishing of synthetic knit fabrics. Process wastewater from the plant are initially treated in a series of three earthen
aeration basins. Following the aeration basins, alum and sodium hydroxide are added in a
rapid mix tank ahead of a flocculator/clarifier. After final pH adjustment, the clarified effluent is discharged to Swatara Creek.
The original wastewater treatment system, which consisted of the aeration basins and a
small sedimentation pond, was unable to meet effluent limitations. Beginning in 1975, Penn
Dye and Finishing Company, with Gilbert/Commonwealth as its consulting engineer, embarked on a program of studies, design and construction to upgrade and expand plant
wastewater treatment facilities. The upgraded system was designed and built to meet all
regulatory requirements of the U.S. Environmental Protection Agency (EPA) and the Pennsylvania Department of Environmental Resources (DER). The expanded industrial wastewater treatment facilities at Penn Dye have been in successful operation since September
1980.
Many small-to-medium size companies, such as Penn Dye, have limited financial resources
available for nonproductive facilities and have little prior experience in wastewater treatment. As a result, extensive investigations are often required to assure management of the
effectiveness of a proposed design. Project phases reviewed for this typical project include
bench scale treatability tests, onsite pilot plant study, obtaining permits, detailed design,
construction, startup and operation.
WASTEWATER FLOWRATES AND CHARACTERISTICS
Textile Dyeing Processes
Penn Dye processes only synthetic fabrics, including acetates, polyesters and nylon. Prior
to dyeing, aU fabric is cleaned and scoured for dirt and oil removal from the knitting process. Mostly dispersed dyes are used.
Both beam dyeing and jet dyeing are employed. In beam dyeing, the fabric is wrapped
around a perforated tube with one end closed and the other connected to a pump discharge.
The beam is immersed in a tub of dye solution, and the pump circulates dye through the
fabric by pumping from the tub into the perforated tube. Jet dyeing, primarily for polyesters, is performed in a closed pressure tub in which the fabric is guided through the dye-
stuff by a series of rollers.
Approximately 85-90% of the wastewater at Penn Dye results directly from the beam
dye machines and jet tubs. The remainder results from cooling water, washers, dryers, boiler
blowdown, filter backwash and other miscellaneous sources. Sanitary wastes are discharged
to the local municipal system.
147